US20160152873A1 - Sheet for forming laminate, and method for producing laminate - Google Patents

Sheet for forming laminate, and method for producing laminate Download PDF

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Publication number
US20160152873A1
US20160152873A1 US14/900,194 US201414900194A US2016152873A1 US 20160152873 A1 US20160152873 A1 US 20160152873A1 US 201414900194 A US201414900194 A US 201414900194A US 2016152873 A1 US2016152873 A1 US 2016152873A1
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Prior art keywords
laminate
sheet
forming
vinyl acetate
eva
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Kazuhiro Omura
Masakuni Watanabe
Masao Hashimoto
Yuji Suzuki
Tatsuya Funaki
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Bridgestone Corp
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Bridgestone Corp
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Assigned to BRIDGESTONE CORPORATION reassignment BRIDGESTONE CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUNAKI, TATSUYA, HASHIMOTO, MASAO, OMURA, KAZUHIRO, SUZUKI, YUJI, WATANABE, MASAKUNI
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
    • C09J123/04—Homopolymers or copolymers of ethene
    • C09J123/08—Copolymers of ethene
    • C09J123/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
    • C09J123/0853—Vinylacetate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
    • C09J5/06—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers involving heating of the applied adhesive
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/10—Adhesives in the form of films or foils without carriers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/12—Photovoltaic modules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2581/00—Seals; Sealing equipment; Gaskets
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
    • C09J2203/322—Applications of adhesives in processes or use of adhesives in the form of films or foils for the production of solar panels
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2301/00—Additional features of adhesives in the form of films or foils
    • C09J2301/30—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
    • C09J2301/304—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier the adhesive being heat-activatable, i.e. not tacky at temperatures inferior to 30°C
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2301/00—Additional features of adhesives in the form of films or foils
    • C09J2301/40—Additional features of adhesives in the form of films or foils characterized by the presence of essential components
    • C09J2301/414—Additional features of adhesives in the form of films or foils characterized by the presence of essential components presence of a copolymer
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2400/00—Presence of inorganic and organic materials
    • C09J2400/10—Presence of inorganic materials
    • C09J2400/14—Glass
    • C09J2400/143—Glass in the substrate
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2423/00—Presence of polyolefin
    • C09J2423/04—Presence of homo or copolymers of ethene
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2431/00—Presence of polyvinyl acetate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention relates to a sheet for forming a laminate, for example, such as a sealing film for a solar cell and an intermediate film for a laminated glass, which is mainly composed of ethylene-vinyl acetate copolymer, to be used for production of a laminate such as a laminated glass and a solar cell module, in particular, a sheet for forming a laminate useful for production of a laminate including a step of application of pressure with nip rolls.
  • a sheet mainly composed of ethylene-vinyl acetate copolymer (hereinafter, also referred to as EVA, and the sheet mainly composed of EVA is also referred to as the EVA sheet) has hitherto been used as a sheet for forming a laminate such as an intermediate film for a laminated glass or a sealing film for a solar cell because the sheet mainly composed of ethylene-vinyl acetate copolymer is inexpensive and has excellent adhesiveness and high transparency.
  • an intermediate film for a laminated glass is held between glass plates 21 A and 21 B, and exhibits a function such as penetration resistance or prevention of scattering of broken glass pieces.
  • FIG. 2 shows a function such as penetration resistance or prevention of scattering of broken glass pieces.
  • a sealing film for a solar cell is disposed between a solar cell element 34 and a front-side transparent protective member 31 formed of a glass substrate or the like, and/or between a solar cell element 34 and a back-side protective member (back cover) 32 , and exhibits a function such as securing of electric insulation or securing of mechanical durability.
  • the EVA sheet can be improved in the properties thereof such as adhesiveness, penetration resistance, and durability by cross-linking the copolymer with a cross-linking agent such as an organic peroxide.
  • a laminate such as a laminated glass
  • materials for a laminate such as a plurality of sheets of glass plates and a sheet for forming a laminate are combined and processed
  • the air present in the boundary surfaces between the sheet for forming a laminate and the glass plates or the like is required to be discharged so as for air bubbles not to occur. This is because when air bubbles are present in a laminate such as a laminated glass, the performance degradation due to the degradation of transparency or the exterior appearance failure sometimes occurs.
  • a method for producing a laminate such as a laminated glass
  • the following methods are used: (1) a method in which a sheet for forming a laminate is held between a plurality of substrates, the resulting laminate is placed in a vacuum bag and deaerated, and pressurized under heating for a preliminary pressure bonding, thus the air present in the sheet for forming a laminate and in the boundaries between the sheet for forming a laminate and the substrates is removed to such a degree that air bubbles remain slightly, and subsequently, the air bubbles are sufficiently removed, by performing final heating and pressurization by using a high temperature-high pressure vessel; (2) a method in which a sheet for forming a laminate is held between a plurality of substrates, the resulting laminate is heated while the laminate is being conveyed so as to pass through a heating zone, then the laminate is held between nip rolls to be pressurized for a preliminary pressure bonding, thus the air in the boundaries between the substrates and the sheet for forming a laminate is squeeze
  • Patent Literature 1 discloses a method for continuously producing a laminated glass by contact pressure exerted by nip rolls, by using an intermediate film made of a resin having specific viscoelastic properties (glass transition temperature, storage modulus of elasticity) and having a thickness falling within a predetermined range, in order to streamline the production process of the laminated glass.
  • Patent Literature 2 also discloses a method in which the air in the laminate is removed by using pressure bonding rolls (nip rolls) as an inexpensive method for producing an amorphous solar cell module.
  • the method of (2) using nip rolls is suitably used when there is used a sheet mainly composed of polyvinyl butyral (hereinafter, also referred to as PVB) generally used as a sheet for forming a laminate such as an intermediate film for a laminated glass.
  • PVB polyvinyl butyral
  • Patent Literature 3 has restrictions on the conditions of the predetermined melt viscosity, surface properties and thickness of an EVA sheet, and hence a further less restrictive method is desired.
  • an object of the present invention is to provide a sheet for forming a laminate, mainly composed of EVA, wherein the sheet allows a sufficient removal of air bubbles in a laminate to be performed by a step of application of pressure by using nip rolls, and allows a satisfactory laminate to be produced.
  • Another object of the present invention is to provide a method for producing a laminate, using the sheet for forming a laminate, mainly composed of EVA, wherein the method allows a sufficient removal of air bubbles in a laminate to be performed by a step of pressurizing the laminate by using nip rolls, and allows a satisfactory laminate to be produced.
  • the laminate is hardly uniformly heated, in such a way that temperature distribution sometimes occurs in the plan view center and the plan view periphery of the laminate.
  • EVA has a tendency for the viscosity thereof to drastically decrease when the temperature reaches a certain temperature, and accordingly when the temperature distribution occurs in the EVA sheet in the laminate, there sometimes occurs a large difference between the viscosities (fluidities) of the EVA in the plan view center and the plan view periphery of the EVA sheet.
  • the above-described object is achieved by a sheet for forming a laminate used in a method for producing a laminate comprising a step of application of pressure by using nip rolls, wherein the sheet for forming a laminate is formed of a composition comprising an ethylene-vinyl acetate copolymer and a cross-linking agent, the content of vinyl acetate in the ethylene-vinyl acetate copolymer is 30% by mass or more in relation to the ethylene-vinyl acetate copolymer, and the melt flow rate according to JIS-K7210 of the ethylene-vinyl acetate copolymer is 5 g/10 min or less.
  • the EVA having such a content of vinyl acetate and a melt flow rate (hereinafter, also referred to as MFR) as described above can be an EVA suppressed in the viscosity variation in relation to the temperature variation in the vicinity of the heating temperature during pressurization with nip rolls. Accordingly, irrespective of the thickness or the like of the sheet, the step of pressurizing the laminate by using nip rolls can sufficiently perform the removal of air bubbles in the laminate, and thus, a sheet for forming a laminate, capable of producing a satisfactory laminate can be produced.
  • the preferable aspects of the sheet for forming a laminate of the present invention are as follows.
  • the content of vinyl acetate in the ethylene-vinyl acetate copolymer is 30 to 50% by mass in relation to the ethylene-vinyl acetate copolymer.
  • the above-described range is preferable because when the content of vinyl acetate is too high, the fluidity of the EVA in the vicinity of the heating temperature during pressurization with nip rolls sometimes becomes too high.
  • the melt flow rate according to JIS-K7210 of the ethylene-vinyl acetate copolymer is larger than 0 g/10 min and 5 g/10 min or less.
  • the above-described range is preferable because when the MFR is too small, the fluidity of the EVA in the vicinity of the heating temperature during pressurization with nip rolls sometimes becomes too low.
  • ⁇ 60° C. and ⁇ 90° C. represent the viscosity at 60° C. and the viscosity at 90° C. of the ethylene-vinyl acetate copolymer, respectively.
  • the ethylene-vinyl acetate copolymer has such physical properties, it is possible to make sufficiently low the probability of the incorporation of air bubbles in the step of pressurizing the laminate by using nip rolls.
  • the viscosity variation rate (r) is 80% or less. The probability of the incorporation of air bubbles can be made further lower.
  • the sheet is an intermediate film for a laminated glass or a sealing film for a solar cell.
  • the degradation of the transparency due to air bubbles hardly occurs, and hence the sheet for forming a laminate of the present invention is most suitable for these applications.
  • the method for producing a laminate of the present invention uses the sheet for forming a laminate of the present invention, and hence, even in the case of an EVA sheet, can sufficiently perform the removal of air bubbles in the laminate by the pressure bonding step of pressurizing the laminate by using nip rolls, and can produce a satisfactory laminate.
  • the pressure bonding step is a step of allowing the laminate to pass through a heating furnace while being conveyed, and then applying pressure to the laminate by allowing the laminate to pass through between a pair of nip rolls.
  • the laminate is heated such that the temperature of the sheet for forming a laminate is 55 to 95° C., before the application of pressure with nip rolls.
  • the laminate is a laminated glass or a solar cell module.
  • the sheet for forming a laminate of the present invention is suppressed, even in the case of an EVA sheet, in the viscosity variation in relation to the temperature variation in the vicinity of the heating temperature during pressurization, and hence, allows the removal of air bubbles in the laminate to be sufficiently performed by the step of application of pressure by using nip rolls. Accordingly, the method for producing a laminate of the present invention allows the laminate using an EVA sheet as a sheet for forming a laminate to be produced efficiently by using a continuous preliminary pressure bonding step, and with a satisfactory yield by suppressing, for example, the occurrence of exterior appearance failure due to the degradation of transparency.
  • FIG. 1 is a schematic cross-sectional view illustrating a representative example of a method for producing a laminate according to the present invention.
  • FIG. 2 is a schematic cross-sectional view of a sheet of a general laminated glass.
  • FIG. 3 is a schematic cross-sectional view of a general solar cell module, (a) represents a solar cell module using a silicon crystal-based solar cell, (b) represents a solar cell module in which a thin-film solar cell element is formed on a front-side transparent protective member, and (c) represents a solar cell module in which a thin-film solar cell element is formed on a back-side protective member.
  • FIG. 4 is a graph illustrating the preferable viscosity-temperature property of the ethylene-vinyl acetate copolymer constituting the sheet for forming a laminate of an embodiment of the present invention.
  • the sheet for forming a laminate of the present invention is a sheet for forming a laminate to be used in a method for producing a laminate, including a step of application of pressure by using nip rolls.
  • the sheet for forming a laminate of the present invention is formed of a composition (EVA composition) comprising at least EVA and a cross-linking agent, the content of vinyl acetate in the EVA is 30% by mass or more in relation to the EVA, and the melt flow rate according to JIS-K7210 of the EVA is 5 g/10 min or less.
  • EVA composition comprising at least EVA and a cross-linking agent
  • the content of vinyl acetate in the EVA is 30% by mass or more in relation to the EVA
  • the melt flow rate according to JIS-K7210 of the EVA is 5 g/10 min or less.
  • the MFR is a value measured under the conditions of 190° C. and a load of 21.18 N.
  • Such an EVA composition can suppress the viscosity variation in relation to the temperature variation in the vicinity of the heating temperature during pressurization with nip rolls. Accordingly, even when the laminate is not uniformly heated before the application of pressure with nip rolls and the temperature distribution occurs in the plan view center and the plan view periphery or the like, there hardly occurs a large difference between the viscosities (fluidities) of the EVA in the plan view center and the plan view periphery or the like of the EVA sheet. Accordingly, the step of application of pressure by using nip rolls allows the removal of air bubbles in the laminate to be performed sufficiently, and thus a sheet for forming a laminate capable of producing a satisfactory laminate can be produced.
  • the content of vinyl acetate in EVA is preferably 30 to 50% by mass, furthermore preferably 30 to 45% by mass and particularly preferably 30 to 40% by mass in relation to EVA.
  • the content of vinyl acetate in EVA is too high, the fluidity of EVA in the vicinity of the heating temperature during pressurization with nip rolls is sometimes too high, or the impact resistance or the penetration resistance of the obtained laminate is sometimes degraded.
  • the MFR of EVA is preferably larger than 0 g/10 min and further preferably 0.1 g/10 min or more.
  • the MFR of EVA is preferably less than 4 g/10 min, further preferably 3 g/10 min or less, and particularly preferably 2 g/10 min or less.
  • the viscosity variation in relation to the temperature variation can be more suppressed in the vicinity of the heating temperature during pressurization with nip rolls.
  • the viscosity range of EVA at 60° C. to 110° C. be 1.0 ⁇ 10 4 to 3.0 ⁇ 10 5 Pa ⁇ s
  • the viscosity variation rate (r) of the ethylene-vinyl acetate copolymer for the temperature change from 60° C. to 90° C. as calculated by the following formula (I) be 90% or less:
  • r represents the viscosity variation rate
  • ⁇ 60° C. and ⁇ 90° C. represent the viscosity at 60° C. and the viscosity at 90° C. of EVA, respectively.
  • EVA having such a narrow viscosity range as described above in a relatively wide temperature range of from 60 to 110° C. hardly causes unevenness in the fluidity of the resin, and hardly incorporates air bubbles.
  • EVA having the above-described viscosity variation rate (r) allows the unevenness of the fluidity to be further hardly caused in the pressurizing step with nip rolls allowing the resin surface temperature to be 60° C. to 90° C., and allows the probability of the incorporation of air bubbles to be sufficiently low.
  • the viscosity variation rate (r) is calculated by using the formula (I′):
  • ⁇ (melting point) represents the viscosity of EVA at the melting point, and the rest is the same as in formula (I).
  • the above-described viscosity variation rate (r) is preferably 80% or less.
  • FIG. 4 shows the viscosity-temperature property of EVA. As shown in FIG. 4 , in the EVA(1) in which the content of vinyl acetate is 33% by mass in relation to EVA and the MFR is 1.0 g/10 min, and the EVA(2) in which the content of vinyl acetate is 32% by mass in relation to EVA and the MFR is 0.2 g/10 min, the viscosity ranges at 60 to 110° C. fall within the above-described range, and the viscosity variation rates (r) are 79% and 87%, respectively, to satisfy the above-described specification.
  • the viscosities in FIG. 4 are the viscosities of EVA(1) to EVA(4) measured by using the viscometer Capilograph ID (furnace diameter: ⁇ 9.55 mm, capillary: ⁇ 1.0 ⁇ 10 mm, manufactured by Toyo Seiki Seisaku-sho, Ltd.) under the condition of a test speed of 1 mm/min, at different temperatures.
  • the sheet for forming a laminate of the present invention allows the air bubbles in the laminate to be sufficiently removed in the pressure bonding step of pressurizing the laminate by using nip rolls, hardly undergoes the occurrence of the degradation of the transparency of the laminate due to the air bubbles in the laminate, and hence can be most suitably used as an intermediate film for a laminated glass for which high transparency is critical, or a sealing film for a solar cell.
  • the cross-linking agent used in the EVA composition can form the cross-linked structure of EVA, and can improve the adhesiveness, strength and durability of the sheet for forming a laminate.
  • an organic peroxide is preferably used.
  • the organic peroxide there can be used any organic peroxide that is decomposed at a temperature of 100° C. or higher to generate radicals.
  • the organic peroxide is selected in consideration of the film formation temperature, the preparation conditions of the composition, the curing temperature, the heat resistance of the adherend, and the storage stability.
  • an organic peroxide is preferable in which the 10 hour half-life decomposition temperature is 70° C. or higher.
  • examples of the organic peroxide include: benzoyl peroxide-based curing agents (such as benzoyl peroxide, 2,5-dimethylhexyl-2,5-bisperoxybenzoate, p-chlorobenzoyl peroxide, m-toluoyl peroxide, 2,4-dichlorobenzoyl peroxide, and t-butyl peroxybenzoate), tert-hexyl peroxypivalate, tert-butyl peroxypivalate, 3,5,5-trimethylhexanoyl peroxide, di-n-octanoyl peroxide, lauroyl peroxide, stearoyl peroxide, 1,1,3,3-tetramethylbutyl peroxy-2-ethylhexanoate, succinic acid peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)he
  • benzoyl peroxide-based curing agents
  • organic peroxides in particular, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, 1,1-bis(tert-hexylperoxy)-3,3,5-trimethylcyclohexane, and tert-butylperoxy-2-ethylhexyl monocarbonate are preferable.
  • organic peroxides a sheet for forming a laminate, having excellent electric insulation is obtained. Such a sheet is effective when used as a sealing film for a solar cell.
  • the content of the organic peroxide is not particularly limited; however, the content of the organic peroxide is preferably 0.1 to 5 parts by mass, and more preferably 0.2 to 3 parts by mass, in relation to 100 parts by mass of EVA.
  • the EVA composition may further include, if necessary, a cross-linking aid.
  • the cross-linking aid improves the gel fraction rate of EVA, and can improve the adhesiveness and the durability of the EVA film.
  • the content of the cross-linking aid used is generally 10 parts by mass or less, preferably 0.1 to 5 parts by mass, and further preferably 0.1 to 2.5 parts by mass, in relation to 100 parts by mass of EVA. Accordingly, there is obtained a sheet for forming a laminate, further excellent in adhesiveness.
  • cross-linking aid (a compound having a radical-polymerizable group as a functional group) may include, in addition to the trifunctional cross-linking aids such as triallyl cyanurate and triallyl isocyanurate, monofunctional or bifunctional cross-linking aids such as (meth)acrylic esters (for example, NK esters).
  • trifunctional cross-linking aids such as triallyl cyanurate and triallyl isocyanurate
  • monofunctional or bifunctional cross-linking aids such as (meth)acrylic esters (for example, NK esters).
  • triallyl cyanurate and triallyl isocyanurate are preferable, and triallyl isocyanurate is particularly preferable.
  • the EVA composition may further include an adhesion improver in order to impart a further excellent adhesion force.
  • a silane coupling agent can be used as the adhesion improver.
  • the silane coupling agent may include: ⁇ -chloropropyltrimethoxysilane, vinyltriethoxysilane, vinyl-tris( ⁇ -methoxyethoxy)silane, ⁇ -methacryloxypropyltrimethoxysilane, vinyltriacetoxysilane, ⁇ -glycidoxypropyltrimethoxysilane, ⁇ -glycidoxypropyltriethoxysilane, ⁇ -(3,4-epoxycyclohexyl)ethyl trimethoxysilane, vinyltrichlorosilane, ⁇ -mercaptopropyltrimethoxysilane, ⁇ -aminopropyltriethoxysilane, and N- ⁇ -(
  • the content of the silane coupling agent is preferably 0.1 to 2 parts by mass, further preferably 0.1 to 0.65 parts by mass, and particularly preferably 0.1 to 0.4 parts by mass, in relation to 100 parts by mass of EVA.
  • the EVA composition may comprise other additives, according to the applications of the sheet for forming a laminate.
  • various additives such as a plasticizer, an acryloxy group-containing compound, a methacryloxy group-containing compound, an epoxy group-containing compound, an ultraviolet absorber, a light stabilizer, and an anti-aging agent may be added to the EVA composition, if necessary, in order to improve or regulate various physical properties (such as mechanical strength, adhesiveness, optical properties such as transparency, heat resistance, light resistance, and cross-linking rate).
  • the addition amount of each of the various additives is preferably within a range of 5 parts by mass or less in relation to 100 parts by mass of EVA.
  • the method for producing the sheet for forming a laminate according to the present invention is not particularly limited and can be produced by forming the above-described EVA composition into a sheet shape by using a heretofore known method.
  • the sheet for forming a laminate according to the present invention can be produced by a method in which the EVA composition is mixed by heating and kneading EVA and a cross-linking agent, and if necessary, the above-described various materials in a super mixer (high speed fluidizing mixer), a twin-screw kneader, a roll mill or the like, and then the mixed EVA composition is molded into a sheet shape by extrusion molding or calender molding (calendering) or the like.
  • a concave-convex shape pattern may be imparted to the surface of the sheet by pressing an emboss roller or an emboss plate against the surface of the sheet.
  • the heating-kneading temperature and the molding temperature are preferably set at the temperatures at which the cross-linking agent does not react or little reacts.
  • the heating-kneading temperature and the molding temperature are 40 to 90° C., in particular, preferably 50 to 80° C.
  • the thickness of the EVA sheet has hitherto been restricted; however, in the case of the sheet for forming a laminate of the present invention, the viscosity variation in relation to the temperature variation is suppressed, and hence the thickness of the sheet for forming a laminate is not particularly limited, and can be appropriately set depending on the application.
  • the thickness of the sheet for forming a laminate is generally in a range from 50 ⁇ m to 2 mm.
  • the sheet for forming a laminate of the present invention may be constituted with an EVA sheet, or may have a multi-layer structure formed by laminating two or more EVA sheets.
  • the method for producing a laminate by using the sheet for forming a laminate of the present invention is described with reference to the accompanying drawings.
  • the method for producing a laminate of the present invention produces a laminate by a step of obtaining a laminate (uncured) by holding the sheet for forming a laminate between two or more sheets of other laminate materials, a step of preliminary pressure bonding the laminate (uncured) by heating the laminate (uncured) and applying pressure to the laminate by using nip rolls, and a step of integration of the laminate by cross-linking by further heating the laminate subsequently (after preliminary pressure bonding).
  • the method for producing a laminate of the present invention uses the sheet for forming a laminate of the present invention, and hence, as described above, even the EVA sheet is suppressed in the viscosity variation in relation to the temperature variation in the vicinity of the heating temperature during pressurization with nip rolls. Accordingly, the pressure bonding step with nip rolls allows the air bubbles in the laminate to be sufficiently removed, and thus, the subsequent heat cross-linking step allows a satisfactory laminate to be produced.
  • FIG. 1 is a schematic cross-sectional view illustrating a representative example of the method for producing a laminate of the present invention.
  • a sheet for forming a laminate 102 is held between two substrates 101 A and 101 B to form a laminate (uncured) 120 .
  • the laminate is allowed to pass through a heating furnace 301 .
  • the heating furnace 301 is equipped with a heater section 302 , and can heat the sheet for forming a laminate 102 until the sheet for forming a laminate 102 reaches the predetermined temperature while the laminate (uncured) 120 is passing through the heating furnace 301 .
  • the laminate (uncured) 120 is allowed to pass between nip rolls 304 constituted with a pair of two rolls facing each other.
  • the nip rolls 304 are an apparatus continuously pressurizing an object passing between the rolls with a predetermined linear load.
  • the laminate (uncured) 120 is pressurized, and the heated sheet for forming a laminate 102 is bonded to the boundary surfaces of the substrates 101 A and 101 B by the application of pressure to the laminate, and thus a laminate (after preliminary pressure bonding) 120 ′ is obtained.
  • the sheet for forming a laminate 102 is formed of the EVA having such a content of vinyl acetate and such an MFR as described above, even when the plan view center and the plan view periphery of the laminate (uncured) 120 are not uniformly heated by the heating furnace 301 and the temperature distribution occurs in the plan view center and the plan view periphery of the sheet for forming a laminate 102 , the fluidity difference between the center and periphery is small, and thus the removal of the air bubbles from the boundary surfaces between the sheet for forming a laminate 102 and the substrates 101 A and 101 B by the step of pressurizing by using the nip rolls 304 is facilitated.
  • the heating furnace 301 For the conveying apparatus 303 , the heating furnace 301 , and the nip rolls 304 , heretofore known, corresponding apparatus, furnace and nip rolls can be used.
  • the heating type of the heater section 32 of the heating furnace 301 can be any type, and examples of the heating type concerned include hot air heating type and infrared ray heating type.
  • a heating apparatus of heat roll type may also be used.
  • the heating is not particularly limited as long as the temperature provided by the heating is the temperature causing no reaction of the cross-linking agent included in the EVA composition of the sheet for forming a laminate 102 .
  • the laminate is heated before the pressurization with the nip rolls in such a way that the temperature of the sheet for forming a laminate 102 falls preferably within a range from 55 to 95° C., furthermore preferably within a range from 65 to 95° C., and particularly preferably within a range from 70 to 95° C.
  • the temperature difference between the plan view center and the plan view periphery of the sheet for forming a laminate is preferably 15° C. or less.
  • the nip rolls 304 can be of any types, and may have a plurality of pairs of nip rolls.
  • the nip rolls may also be constituted with heat rolls in order to avoid the temperature decrease during pressurization.
  • the linear load exerted by the nip rolls 304 is not particularly limited; however, the linear load is preferably 5 to 100 kN/m and furthermore preferably 10 to 50 kN/m.
  • a laminate can be obtained by performing, after the above-described pressure bonding step, a cross-linking integration step (heat cross-linking step) of heating the laminate (after preliminary pressure bonding) 120 ′.
  • the heat cross-linking step can use a heretofore known method.
  • a high temperature-high pressure treatment such as a treatment using an autoclave or the like can be used.
  • the heating conditions are not particularly limited, and also regulated by the mixing proportion of the cross-linking agent or the like included in the above-described EVA composition.
  • the heating is performed at 100 to 155° C. (in particular, in the vicinity of 130° C.) for 10 minutes to 1 hour.
  • the heating is preferably performed while pressurizing at a pressure of 1.0 ⁇ 10 3 Pa to 5.0 ⁇ 10 7 Pa.
  • the cooling of the laminate after cross-linking is generally performed at room temperature, and in particular, the more rapid the cooling is, the more preferable. Air bubbles have been sufficiently removed from inside the laminate (after preliminary pressure bonding) 120 ′ by the pressure bonding step of pressurizing by using nip rolls, and accordingly, a satisfactory laminate can be obtained by the heat cross-linking step.
  • the removal of the air bubbles in the laminate can be sufficiently performed in the pressure bonding step of pressurizing by using nip rolls, the degradation of the transparency of the laminate due to air bubbles hardly occurs, and hence the method for producing a laminate of the present invention is suitable for the production of a laminated glass or a solar cell module required to have high transparency as a laminate.
  • the sheet for forming a laminate of the present invention is used, as the intermediate film 22 for a laminated glass, of the laminated glass shown in FIG. 2 , and the transparent substrates 21 A and 21 B can be produced as other laminate materials according to the method for producing a laminate shown in FIG. 1 .
  • the sheet for forming a laminate is held between the two sheets of the transparent substrates such as two sheets of glass plates to form a laminate (uncured), the laminate is heated, then the laminate is preliminarily bonded by the application of pressure to the laminate with nip rolls and further heated to be integrated by cross-linking, and thus the laminated glass is produced.
  • transparent substrates in addition to glass plates such as green glass, silicate glass, inorganic glass plate, and uncolored transparent glass plate, for example, substrates or films made of plastics such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyethylene butyrate, polymethyl methacrylate (PMMA) may also be used. Glass plates are preferable from the viewpoint of heat resistance, weatherability, impact resistance and the like.
  • the thickness of the transparent substrate is generally approximately 0.1 to 20 mm. As the two sheets of transparent substrates, the same type of substrates may be used, or alternatively, a combination of different types of substrates may also be used.
  • the solar cell module can be produced according to the method for producing a laminate shown in FIG. 1 , by using the sheet for forming a laminate of the present invention as the sealing films for a solar cell (front-side sealing film 33 A and/or back-side sealing film 33 B) in the solar cell modules shown in FIGS. 3( a ) to 3( c ) , and by using the front-side transparent protective member 31 , the solar cell elements 34 , and the back-side protective member 32 , as other laminate materials.
  • the front-side transparent protective member, the sheet for forming a laminate (sealing film), the solar cell elements (cells for solar cell), the sheet for forming a laminate (sealing film), and the back-side protective member are laminated in this order; in the case of the solar cell module of FIG. 3( b ) , the sheet for forming a laminate (sealing film) is held between the front-side transparent protective member on the surface of which a thin film solar cell element is formed and the back-side protective member; and in the case of the solar cell module of FIG.
  • the sheet for forming a laminate is held between the front-side transparent protective member and the back-side protective member on the surface of which the thin film solar cell element is formed; thus, in each of these cases, a laminate (uncured) is formed, the laminate is heated, then the heated laminate is pressurized by using nip rolls to be subjected to preliminary pressure bonding, then the laminate is heated to be subjected to cross-linking integration, and thus a solar cell module is produced.
  • Examples of the solar cell element include: a single crystalline or polycrystalline silicon crystal-based cell for a solar cell in the case of the cell for the solar cell module of FIG. 3( a ) ; and thin film silicon-based solar cell, thin film amorphous silicon-based solar cell, and copper indium selenide (CIS)-based solar cell element in the cases of the thin film solar cell elements of FIGS. 3( b ) and 3( c ) .
  • a single crystalline or polycrystalline silicon crystal-based cell for a solar cell in the case of the cell for the solar cell module of FIG. 3( a )
  • thin film silicon-based solar cell, thin film amorphous silicon-based solar cell, and copper indium selenide (CIS)-based solar cell element in the cases of the thin film solar cell elements of FIGS. 3( b ) and 3( c ) .
  • the front-side transparent protective member examples include a glass substrate such as a silicate glass substrate, a polyimide substrate, and a fluororesin-based transparent substrate.
  • a glass substrate is preferable, and the glass substrate may be a chemically or thermally reinforced substrate.
  • the thickness of the transparent substrate is generally 0.1 to 10 mm, and preferably 0.3 to 5 mm.
  • a film of a plastic such as polyethylene terephthalate (PET) is preferably used.
  • PET polyethylene terephthalate
  • polyethylene fluoride film in particular, a film obtained by laminating polyethylene fluoride film/Al/polyethylene fluoride film in this order may also be used.
  • compositions having the formulations listed in Table 1 and Table 2 were kneaded with a roll mill at 60 to 70° C., and were shaped by calendering at 70° C. to prepare sheets for forming a laminate (thickness; 0.5 mm).
  • Laminates (uncured) were formed in each of which the sheet for forming a laminate was held as an intermediate film between two sheets of glass plates (size: 1000 mm ⁇ 1000 mm, thickness: 3 mm), each of the resulting laminates was heated in such a way that the temperature of the sheet for forming a laminate listed in Table 1 or Table 2 was obtained, by using the heating apparatus (hot air heating type) and the pressure bonding apparatus having the pressurizing apparatus with nip rolls (see FIG. 1 ). Then each of the heated laminates was subjected to the preliminary pressure bonding and then subjected to a pressurizing treatment under the condition of a temperature of 135° C. for 60 minutes with an autoclave, and thus, sheets of laminated glass were prepared.
  • the heating apparatus hot air heating type
  • the pressure bonding apparatus having the pressurizing apparatus with nip rolls
  • the temperature of each of the sheets for forming a laminate was measured as follows: a temperature indicator seal was attached to each of the plan view center and the plan view periphery of the sheet for forming a laminate, before the formation of the laminate, and the indicated temperature of the temperature indicator seal was measured.
  • Example 2 Com- EVA(1)* 1 100 100 100 100 100 100 100 — — — — — — — — posi- EVA(2)* 2 — — — — — — 100 100 100 100 100 100 100 100 100 100 100 tion EVA(3)* 3 — — — — — — — — — — — EVA(4)* 4 — — — — — — — — — — — — — — — — — Cross-linking agent* 5 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
  • Ultraviolet absorber* 8 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
  • laminates such as sheets of laminated glass and solar cell modules can be provided by using a sheet for forming a laminate, including EVA inexpensive and excellent in adhesiveness and transparency.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Power Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Laminated Bodies (AREA)
  • Photovoltaic Devices (AREA)
  • Joining Of Glass To Other Materials (AREA)
  • Adhesive Tapes (AREA)
  • Adhesives Or Adhesive Processes (AREA)
US14/900,194 2013-06-28 2014-06-27 Sheet for forming laminate, and method for producing laminate Abandoned US20160152873A1 (en)

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PCT/JP2014/067281 WO2014208756A1 (fr) 2013-06-28 2014-06-27 Feuille pour la formation de stratifié et procédé pour la production de stratifié

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CN106057976A (zh) * 2016-07-28 2016-10-26 陈应天 一种利用冷封装制造光伏组件的方法
EP3753910A4 (fr) 2018-02-14 2021-11-17 Dow-Mitsui Polychemicals Co., Ltd. Composition de résine pour film de couche intermédiaire de verre feuilleté ou matériau d'encapsulation de cellule solaire, film de couche intermédiaire de verre feuilleté, verre feuilleté, matériau d'encapsulation de cellule solaire, et module de cellule solaire
CN108749015B (zh) * 2018-05-11 2020-06-19 横店集团东磁股份有限公司 一种高磁导率吸波厚片的制备方法
CN117691001A (zh) * 2024-02-02 2024-03-12 晶科能源(海宁)有限公司 光伏组件层压机和光伏组件的层压方法

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